This info was posted in another sticky but I wanted to repost it here and add some things I found. Thanks to metroplex for posting it first.
************************************************** ***********************
Make : CHEVROLET Model : COBALT SS Year : 2008
Manufacturer : GENERAL MOTORS CORP.
Service Bulletin Number : PIP-4485 Date of Bulletin : OCT 01, 2008
NHTSA Item Number : 10026690
Component : ENGINE AND ENGINE COOLING:COOLING SYSTEM:RADIATOR ASSEMBLY
Summary :
GMC: LOW BOOST, REDUCED POWER AND/OR DTC ON CERTAIN 2008-09 COBALT SS. INSPECT THE RIGHT SIDE CAC (CHARGE AIR COOLER) PIPE FOR CONTACT ON RADIATOR SUPPORT BOLT. *PE
Check to Request Research. Submit below.
Make : CHEVROLET Model : COBALT SS Year : 2008
Manufacturer : GENERAL MOTORS CORP.
Service Bulletin Number : PIP-4485 Date of Bulletin : OCT 01, 2008
NHTSA Item Number : 10026690
Component : ENGINE AND ENGINE COOLING:COOLING SYSTEM:HOSE
Summary :
GMC: LOW BOOST, REDUCED POWER AND/OR DTC ON CERTAIN 2008-09 COBALT SS. INSPECT THE RIGHT SIDE CAC (CHARGE AIR COOLER) PIPE FOR CONTACT ON RADIATOR SUPPORT BOLT. *PE
Check to Request Research. Submit below.
Make : CHEVROLET Model : COBALT SS Year : 2008
Manufacturer : GENERAL MOTORS CORP.
Service Bulletin Number : 08-200 Date of Bulletin : JUN 01, 2008
NHTSA Item Number : 10026606
Component : ENGINE AND ENGINE COOLING:ENGINE
Summary :
GMC: ENGINE OIL PAN DRAIN PLUG THREAD INSERT LOOSE OR DAMAGED-INSPECT/INSTALL NEW INSERT. VEHICLES MAY HAVE AN UNDERSIZE ENGINE OIL PAN DRAIN PLUG THREAD INSERT THAT WILL BE INSTALLED TOO FAR INTO THE OIL PAN HOLE. *PE CSC LETTER WAS RECEIVED. UPDATED 12/1/08. *PE

Here it is for 2009:

I realize they're just repeats, but I wanted to post everything I got off the NHTSA site:

Make : CHEVROLET Model : COBALT SS Year : 2009
Manufacturer : GENERAL MOTORS CORP.
Service Bulletin Number : PIP-4485 Date of Bulletin : OCT 01, 2008
NHTSA Item Number : 10026690
Component : ENGINE AND ENGINE COOLING:COOLING SYSTEM:RADIATOR ASSEMBLY
Summary :
GMC: LOW BOOST, REDUCED POWER AND/OR DTC ON CERTAIN 2008-09 COBALT SS. INSPECT THE RIGHT SIDE CAC (CHARGE AIR COOLER) PIPE FOR CONTACT ON RADIATOR SUPPORT BOLT. *PE
Check to Request Research. Submit below.
Make : CHEVROLET Model : COBALT SS Year : 2009
Manufacturer : GENERAL MOTORS CORP.
Service Bulletin Number : PIP-4485 Date of Bulletin : OCT 01, 2008
NHTSA Item Number : 10026690
Component : ENGINE AND ENGINE COOLING:COOLING SYSTEM:HOSE
Summary :
GMC: LOW BOOST, REDUCED POWER AND/OR DTC ON CERTAIN 2008-09 COBALT SS. INSPECT THE RIGHT SIDE CAC (CHARGE AIR COOLER) PIPE FOR CONTACT ON RADIATOR SUPPORT BOLT. *PE
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I found this condition on mine and took some photos. As well as the radiator support bolt rubbing on the charge air piping, I had another spot where it was rubbing on the fan shroud.



I removed the bolt and cut about 3/8" off of it as it was much too long. Loosened lower IC clamp and repositioned the hose a bit to allow enough clearance to add some closed cell foam (pipe insulation) between the fan shroud and IC piping. The next image shows where the shroud was rubbing from above.



This image shows the foam installed from underneath.



I hope this helps others resolve the issue before it becomes a hole in the charge piping.

 

i will look today at 6

 

I just took off my stock piping last night and noticed that the little hose that goes from the cold side piping to the MAP sensor was rubbing on something too pretty badly (I think on another hose or the fan shroud) it is worn half through so everone check that too. If that leaks the MAP will not read correctly the A/F ratio will go crazy and so will the boost levels too.

 

Do you have a picture of this???

 

No, but if you look at the OP pics you see the little rubber hose with the green clip on it? It is clearly touching the fan shroud in the pic. look where the two rubber hoses cross in the image and you will see what I mean.

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Yea man. It just looks like I will have to get up under my hood & look for it...

Thanks!!!!

 

Definately. Mine is worn half through at only 6K miles. I am going to put something beween the hose and the shroud to stop it.

 

WOW! Yea, I'm just about to pop my hood now & look for it. I have like 4,200 miles. I bought it at the end of September. I really don't drive mine that much...

 

Same here. I bought mine in the beginning of July. I drive my work truck most of the time. Free gas FTW.

 

I have ~16k miles, I should probably check...kinda cold outside though.

 

Yea. Mine has very little rubbing on it. Almost non-existant.

 

Where did you get the foam from?? im gunna need to do this too

 

Looks like the foam they use to insulate water pipes. Lowes or HomeDepot will have what you need.

 

^^^^^ What he said

The MAP sensor tubing on mine was barely marked from the fan shroud. Pulling a little slack out of the hose through the retaining clip above made enough clearance between that hose & the shroud so it won't rub anymore. Thanks for mentioning that too.

 

So to fix a rubbing issue, they put a peice of foam inbetween those 2 things? Wow cheapos

 

No, I repositioned the charge tubing so it wouldn't rub and added the foam in case it would touch again under vibration & load. Sorry if I was unclear.

 

Your welcome. Mine is rubbing pretty bad. If I left it unchecked for another 6K miles there would definately be a hole in it. Glad i got my CIA chargepiping now rather than later. I am going to pull the slack out like you suggested and I am going to put something over the tube to protect it too.

 

Ah ok. I thought it was a Chevy fix for an issue. Makes sense now

 

Now im happy i got Dejons IC piping

 

good info

 

good info

 

good info

 

I beat the hell out of the 'Balt yesterday on the ride home and everything is still in place ok. I guess it'll hold until I get charge piping.